Steel structure workshop management process and system

I. General Provisions

(I) Purpose of the System
This management process and system are specially formulated to ensure the normal production order of the Steel structure workshop, improve product quality, increase production efficiency, reduce production costs, and ensure safe production. By clarifying the requirements and specifications of each link, the overall operation of the workshop will be more orderly and efficient, and each production step will have rules to follow, so as to ensure that the steel structure products can be delivered with high quality to meet the market and customer needs.

(II) Scope of Application
This management process and system is applicable to all staff in the Steel structure workshop, covering all production links from the entry of raw materials into the workshop to the output of finished products, including but not limited to the storage and use of materials, unloading, welding, hole making, straightening, rust prevention and other operating procedures, as well as the use and maintenance of equipment involved in the workshop, on-site environmental management and other related aspects.

II. Personnel Management Requirements

(I) Attendance System
All staff in the steel structure workshop must strictly abide by the work and rest time stipulated by the company. Normal working hours are [specific working time intervals, such as 8:00-12:00 in the morning and 13:30-17:30 in the afternoon]. Workshop employees should arrive at their posts in advance and prepare for work.

The leave application process must be standardized. If you need to apply for leave due to special circumstances, you should apply for leave in writing to your direct supervisor at least 2 hours in advance. Leave duration within 1 day must be approved by the team leader; leave duration within 3 days must be approved by the workshop supervisor; and leave duration exceeding 3 days must be approved by the project manager. If you are unable to apply for leave in advance due to an emergency such as illness, you must submit a doctor's certificate afterwards, otherwise it will be treated as absenteeism, and private leave or approval of leave outside working hours will be prohibited.

There are also clear handling methods for lateness, early departure, and absenteeism. If you are late or leave early within 15 minutes, you will be warned and recorded; if you are late or leave early for more than 15 minutes, your salary will be deducted according to the corresponding time. If you are absent from work for half a day, double the wages for that day will be deducted. If you are absent from work for 3 days or more in a row, it will be considered as automatic resignation, and the wages for that month will not be settled. In addition, you will be held accountable according to the losses caused to the workshop.

At the same time, the workshop will regularly count the attendance and link the attendance results with the employee's performance, bonuses, etc. to ensure that every employee can arrive on time to participate in production and ensure the smooth progress of the workshop's production tasks.

(II) Dress and behavioral norms
In terms of dress, the steel structure workshop staff has strict requirements. You must wear uniform work clothes when entering the workshop. The work clothes must be kept clean, undamaged, and of the right size. They should not be too tight or too loose when worn. Zippers, buttons and other parts should be fastened and not left open, and they must not be put on the shoulders or tied.

In addition, according to work safety needs, staff must wear safety helmets when working in the workshop, and wear corresponding protective gloves, protective glasses and other labor protection supplies when performing specific operations.

In terms of behavioral norms, smoking, eating snacks and other behaviors are strictly prohibited in the workshop to keep the workshop environment safe and hygienic. Do not litter or scribble in the workshop at will. Materials, tools, etc. must be placed neatly in the specified positions. After work, you must tidy up the products, materials and work surfaces of your own position. If you need to leave your post during working hours, you must obtain the consent of the team leader before leaving, and you must strictly follow the operating procedures. You must not damage materials, tools and equipment at will. Once you violate the relevant behavioral norms, you will be punished accordingly depending on the severity of the circumstances. The purpose is to show the good working style of the workshop and ensure the orderly production.

III. Control of production links

(I) Raw material control
The source of steel structure workshop production lies in raw materials. Controlling the quality of raw materials is the basis for producing high-quality steel structure products. First of all, you should choose regular manufacturers with quality certificates to purchase raw materials to ensure that the quality of steel meets the relevant national standards and design requirements. For steel plates used in key parts, sampling and re-inspection must be carried out in accordance with regulations to check whether their chemical composition, mechanical properties and other indicators meet the standards. At the same time, when the raw materials enter the site, the surface condition of the metal materials should be carefully checked to see if there are defects such as cracks, rust, and peeling. If there are any defects that do not meet the requirements, the supplier should be communicated and handled in a timely manner. Unqualified raw materials are strictly prohibited from entering the subsequent production links.

(II) Unloading process
The unloading process must strictly follow the process requirements. Different cutting machines have corresponding cutting allowance standards. For example, when the southern machine uses a 0# cutting nozzle, the cutting allowance is 2mm, and the northern machine uses a 2# cutting nozzle. It is 3mm, and 5-10mm cutting edge excess must be reserved to prevent uneven heating and deformation of the edge. Before unloading, the operator must carefully review the drawings, select the correct plate type (material, thickness), use the overhead crane to lift the steel plate to the cutting platform, and ensure that the plate edge is parallel to the cutting machine track, determine the spacing of the cutting nozzle (plus the cutting allowance), and adjust the height of the cutting nozzle. After the starting end is preheated, start cutting. During the process, the cutting speed should be reasonably adjusted according to the thickness of the steel plate. For the cutting of variable-section webs, it is also necessary to use tools such as box rulers and steel rulers to draw angle templates, determine the cutting position according to the lines, etc., to ensure accurate and standardized cutting.

(III) Welding quality control
The welding quality is directly related to the overall stability and safety of the steel structure. Welders engaged in welding work must have corresponding qualification certificates to ensure that their skill levels meet the requirements. Before welding, check the assembly quality of the components and check whether the weld gap is too large. If it is too large, the gap must be repaired or rejected. At the same time, clean the weld impurities, check the operation of the welding equipment, and check whether the welding wire and flux are sufficient. During the welding process, it is necessary to adjust the appropriate welding parameters, such as welding voltage, welding current, welding speed, etc., and ensure that the welding wire is directly above the weld and at a suitable height from the weld. Always pay attention to whether the weld is offset. Once offset occurs, adjust the welding wire in the opposite direction in time. After welding is completed, clean the welding slag covering the weld, check the welding quality, and perform manual arc welding on the defective parts to ensure the quality of the repair welding.

(IV) Hole-making process
Hole-making is a very important part in steel structure processing. First, carefully review the drawings to determine the plate thickness and geometric dimensions of each hole-making part, then hoist the plate that meets the specifications of the drawings, and clean the impurities such as iron oxide on the plate. Then select a plate as a sample, determine the two reference edges of the sample hole, and determine the center of the hole along the reference edge in turn (using a sharpened stone pencil or a stylus), make a hole in the center of each hole, and report to the workshop quality inspector to inspect the sample. Only when the sample is qualified can the hole be made. When making holes, put the plates of the same specification on the drilling machine, with the sample on the top, to ensure that the reference edges of each plate are flat, select a drill bit of the same specification as the drawing requirements (if there is no suitable drill bit, use a drill bit one size larger than the drawing requirements), first use the positioning pin to find the hole on the sample, lock the drilling machine, replace the drill bit, turn on the cooling water, and start making holes. Subsequent hole-making parts of the same specification are all positioned by using the sample holes on the first batch. In addition, different hole making methods such as mechanical hole making and flame cutting hole making should be carried out according to their respective operating procedures and precautions. For example, mechanical hole making should pay attention to iron chip splashing, scalding, high-speed rotation entanglement and other problems; flame cutting hole making should be cut along the line according to the gas cutting technical specifications.

(V) Straightening process
Common forms of straightening processes include flame correction. Taking flame correction as an example, before correction, preparations should be made, oxygen, acetylene, tools, and equipment should be checked, suitable welding nozzles should be selected, the material of the component to be corrected should be understood, the cause of deformation should be found, the deformation direction and size of H-shaped steel should be determined by visual inspection, and the deformation size of the connecting plate at the end of the beam should be measured with a ruler. Determine the heating position and heating sequence. Generally, the position with large deformation should be corrected first, and the heating range and heating temperature should be determined (the heat correction temperature of low carbon steel and low alloy steel is generally 600-900℃). Then, heating correction should be carried out, the correction quality should be checked, and the range that fails to meet the quality requirements should be flame corrected again to ensure that the flatness deviation of the connecting plate at the end of the beam is within 2mm. Through these steps, ensure that the shape of steel structure components meets the standard requirements.

(VI) Anti-rust treatment control
In order to improve the corrosion resistance of steel, the anti-rust treatment link cannot be ignored. When removing rust, it is necessary to select appropriate rust removal tools to meet the relevant quality standards and process requirements. When shipping steel structure components, the components should be numbered, and corresponding measures should be taken to protect the components and coatings to avoid damage during transportation and other processes, which will affect the anti-rust effect. For example, covering and isolation can be used to prevent the surface coating of the components from being scratched or collided and falling off, so as to ensure that the steel structure components can better resist the erosion of the external environment and extend their service life.

IV. Quality inspection and feedback

(I) Key points of quality inspection link
After the completion of each production link, quality inspection is crucial. The key items and inspection standards are as follows:

Raw material inspection: Check the steel quality certificate, take samples of key parts of the steel plate according to regulations to re-test the chemical composition, mechanical properties and other indicators, check whether there are cracks, rust, peeling and other defects on the surface of the metal material, and ensure that the raw materials meet the relevant national standards and design requirements.

Inspection of cutting process: check whether the cutting allowance is carried out according to the corresponding machine and cutting nozzle standards, check whether the cutting size is accurate, whether the angle template drawing and cutting position determination of the variable-section web cutting are accurate, whether the plate edge is parallel to the cutting machine track, etc.

Inspection of welding quality: check the welder's qualification certificate, check the assembly quality of the components, such as whether the weld gap is appropriate, whether the parameters are properly adjusted during welding, whether the wire position and height are correct, whether the weld is offset, and the quality of welding slag cleaning and repair welding after welding.

Inspection of hole making process: review the drawings to determine the relevant specifications of the hole making parts, whether the reference edge, hole center positioning and eye-opening operations of the sample hole making are accurate and standardized, whether the drill bit is suitable, whether the plate placement and positioning during the hole making process and the subsequent hole positioning of the same specification hole making parts are accurate, and whether different hole making methods are carried out according to the corresponding processes and precautions.

Straightening process inspection: Taking flame correction as an example, check the oxygen, acetylene, tools, equipment, heating position, sequence, range and temperature, whether the quality of the corrected components meets the standard requirements, such as whether the flatness deviation of the connecting plate at the end of the beam is within 2mm.

Anti-rust treatment inspection: Check whether the selection of rust removal tools meets the quality standards and process requirements, whether the component number and protection measures are in place during shipment, whether the surface coating of the component is damaged, etc.

The responsibility of the quality inspector is to strictly follow the above standards and conduct detailed inspections on the products after each process is completed. The inspection process is: the workshop workers first report to the quality inspector after the process is completed. The quality inspector brings the corresponding measuring tools and testing equipment to the site, and checks and tests one by one according to the inspection standards. For the qualified products, sign and confirm to enter the next process. If unqualified products are found, they will be immediately marked and issued with an unqualified report, requiring the relevant responsible persons to make timely rectifications. After the rectification is completed, it needs to be reported again until the product quality meets the standards, so as to ensure that the quality of the products produced by the steel structure workshop is qualified and meets the delivery requirements.

(II) Problem feedback mechanism
When quality problems or other emergencies occur during the production process of the workshop, an effective feedback mechanism must be established. Workshop personnel can provide feedback through the following channels and methods:

Oral feedback: If an urgent quality problem is found at the production site, the operator can immediately report it to the team leader orally. The team leader must arrive at the site to check the situation as soon as possible. If the problem exceeds his or her ability to handle it, he or she must immediately provide feedback to the workshop supervisor.

Written feedback: For some non-urgent but more important quality problems, workshop personnel can fill out a special quality problem feedback form, detailing the process, location, manifestation, and initial cause of the problem, and submit it to the workshop quality inspector or directly to the workshop supervisor.

After receiving the feedback, the relevant departments will quickly start the follow-up processing process. The workshop supervisor should organize technical personnel, quality inspectors, etc. to analyze and evaluate the problem together, formulate a rectification plan, and clarify the person responsible for rectification and the rectification period. The person responsible for rectification must strictly follow the requirements of the plan to make rectifications. During the rectification process, the quality inspector must do a good job of supervision and inspection to ensure that the rectification is in place. After the rectification is completed, the inspection will be carried out again. If it is qualified, the records will be filed. If it is still unqualified, the reasons need to be re-analyzed and the rectification will continue until the problem is completely solved to ensure that the workshop production can continue normally and the product quality is stable and reliable.

V. Equipment and Environmental Management

(I) Equipment Operation and Maintenance
All types of equipment in the steel structure workshop must be used strictly in accordance with the safety operating procedures. Before operation, the operator must undergo professional training, be familiar with the working principle, operation method and emergency treatment measures of the equipment, and obtain the corresponding qualifications before going to work. During the operation, the operator must always stay focused, and it is strictly forbidden to operate in violation of regulations and overload the equipment.

Daily maintenance of equipment is essential. For example, for a gantry-type automatic submerged arc welding machine, it is necessary to check daily whether the fan rotates smoothly, whether there are abnormal noises, odors, overheating and discoloration during operation, and whether the primary and secondary groundings are firm and not loose; dust bags, welding slag and other debris in the flux recovery device should be cleared every week, the guide rail surface and the surrounding environment should be checked, and the guide wheel should be adjusted regularly to make the guide wheel and the guide rail surface fit closely; the welding power output should be tested every month, and the electrical components should be checked to see if they are normal, and the dust in the electric cabinet should be removed. For a flame linear cutting machine, it is also necessary to regularly check whether the gas system is leaking, whether the gas pipe is aging, wipe the guide rack and add lubricating oil, check the track straightness and the verticality of the machine, etc.

Different equipment has different maintenance cycles and key projects. In short, regular maintenance should be carried out to ensure the normal operation of the equipment, reduce the equipment failure rate, extend its service life, and provide strong support for the efficient production of the steel structure workshop.

(II) Workshop Environmental Sanitation
The environmental sanitation of the steel structure workshop must meet certain standards. In terms of garbage disposal, garbage should be classified and stored, and waste materials, scraps and other garbage generated during the production process should be cleaned up in time to keep the workshop passages smooth to avoid the accumulation of debris affecting production and personnel passage.

Floor cleaning requires daily cleaning and regular deep cleaning. When cleaning, steel wool, brushes and other abrasive cleaning products should not be used to prevent damage to the floor. For equipment cleaning, oil, dust, iron filings, etc. on the surface of the equipment should be cleaned in time after use to prevent them from entering the equipment and affecting performance. At the same time, the equipment should be cleaned and maintained comprehensively on a regular basis.

In terms of ventilation, it is necessary to ensure good air circulation in the workshop, especially in welding, painting and other process areas that are prone to produce harmful gases. Effective